Rapid action coater

ABSTRACT

A new device and process for continuously applying coatings, such as resin and additives or polymers or the like, to minerals is disclosed. The device and apparatus differ substantially from standard batch coating processes currently used by industry. The apparatus uses a horizontal cylinder with an internal auger and a series of injection ports distributed along the cylinder. Minerals that are to be coated are pretreated and passed through the mixing cylinder using the auger (which may comprise one or more screws with variable pitch blades). As the mineral particles pass through the cylinder various coating materials are injected by the injection ports. The complete system is described, the method of use is explained and the control system which allows for different products is described.

Priority is claimed from International Application NumberPCT/US2005/029008 with an international filing date of 15 Aug. 2005 witha priority date of 17 Aug. 2004. This application is made under 35U.S.C. § 371.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to an improved process forcoating sand, ceramic and other substrates with novalac resins and othercoatings. More particularly it relates to an apparatus and method for acontinuous rapid coating process as opposed to current processes thatuse batch coating.

BACKGROUND OF THE INVENTION

The prior art will be described in terms of resin coated sand used inthe Shell Process employed by the metal casting and foundry industry.The shell process was developed in Germany during the Second World War,and the process was used to produce molds for mortars, artillery shellsand other projectiles. The Germans attempted to keep the process secretafter the war; however, the process was discovered by alliedinvestigators who placed the process in the public domain as war bootywhich then provided the foundry industry with a revolutionary process.

The Shell Process (also known as the Croning or C Process) is used toproduce hollow light weight molds and cores for pipe hubs, cores, crankshafts, intake manifolds for engines, etc. In fact, more foundriesutilize the shell process, to produce resin sand cores and molds, thanany other process. The process is extensively applied worldwide.

The original process blended raw sand with powdered phenolic resin andpowdered hexamethylenetetramine (a curing agent) which was gravity fedinto a preheated pattern. The heat melted the resin and hardener to fusethe sand. After a suitable thickness of sand was obtained, theunactivated sand was dumped from the pattern, leaving the hollow coresand mold. As time went by, the process was improved by pre-coating thesand with the required ingredients (resin—hardener—wax—fillers—etc.) ata sand facility. The “foundry sand” is then sold as a free-flowingproduct to foundries (or foundries produce their free-flowing product).

The current state of the art uses batch mixers to coat substrates(minerals, ceramics, etc.) with a resin(s) and other ingredients. Thatis, sand is preweighed, heated to the desired temperature andtransferred into a batch mixer. Resin(s) and additives are then addedsequentially and held in the mixer until the material has reached therequired cure stage or begins to break down into smaller agglomeratedclumps of sand and resin. The mixture is then dumped and the cycle isrepeated.

U.S. Pat. No. 4,439,489 to Johnson et al. discusses several processesfor coating proppants (a substrate used in the oil industry) all ofwhich use a batch process. U.S. Pat. No. 4,090,995 to Smillie describesanother batch process used to coat sand for use in shell molds. It isinteresting to note that the resin acts in proppants and shell sands ina similar manner—that is the resin acts to hold the substrate in a fixedshape, or to strengthen the substrate. Thus, the techniques used to coatproppants or industrial sand is similar.

It is well known that batch processes are time consuming. For example,the assignee currently uses 1000-1200 pound [455-546 kg] pug mixer withincluded mixer paddles at its Bridgman, Mich. plant. (See FIG. 1) Thetypical batch mixer cycle is 3-5 minutes depending on productformulation. Approximately 15 seconds of non-productive time isexperienced as each batch is discharged, and a new sand charge is addedto the mixer. Thus, the mixer can only produce 1200 pounds [546 kg]times every 3-5 minutes or around 144,000 pounds [65,455 kg] per shift.It is believed that if the process is modified to be a continuous mixerprocess, the mixer would be capable of operating at significantly higherproduction rates.

There are other problems with the batch process explained above. Heatedsand is dropped in the batch mixer, and the required resins and otheringredients are added to the mixer with the paddle stirring the mix.Minutes into the mixing process, hexamethylenetetramine (hexa—the curingagent or hardener) solution is added along with water and wax. At thisstage the mix agglomerates (goes from a free mixing sand to a materialthat looks like stiff bread dough), thus reducing the probability of aneven coat of the particles. The mixing process continues therebybreaking up most of the agglomerated mixture. The portion of the mixturethat does not break up is sent to a roll crusher (or similar device)that breaks up chunks of particle mix eventually producing a freeflowing product. It should be remembered that the foregoing example isfor a 1200 pound [546 kg] batch type mixer. Various sizes of batch typemixers will yield different production rates.

There are several manipulative stages involved following the batch mixprocess used to create a free flowing product, and these stages requireconsiderable transfer of the material through various material handlingsystems and various physical levels within the process plant therebyexpending considerable energy. The process described above is for asingle coating and often (particularly for “frac-sand”) the substrate iscoated a second and even a third time.

The concept behind a resin coated substrate is to obtain a uniformcoating on each particle. In order to coat a particle, the substrate isheated to obtain a surface temperature hot enough to melt the resinwhile not heat soaking the particle. The curing agent is then broughtinto contact with the heated particle. If the particle remains hot, thenthe resin will cure (referred to as the “C-stage”); however, if theparticle is quenched, then the resin will only partially cure (referredto as the “B-stage”). Thus, in the coating process the use of solutioncuring agents (hexa in solution) is paramount. The water in the solutionremoves the heat from the particle. Some resins require a higher meltingtemperature, thus, more heat must be removed and additional water isadded after adding the curing agent. In some cases additional cooling isrequired and air or a cooling water jacket is be used.

Thus, there remains a need to convert batch resin coating processes tocontinuous processes thereby increasing productivity and reducing energyuse while maintaining or even improving product quality.

SUMMARY OF THE INVENTION

The actual invention consists of an extended cylindrical conduit, thatmay take a trough-like shape (a cylinder with lobes), and that may bedivided into one or more segments thereby forming the continuous mixer.The simplest embodiment of the continuous mixer, employed in a rapidaction coater, is a single segment. Further the simplest continuousmixer has a lateral set mixing paddles extending through the center ofthe cylindrical conduit, attached to a paddle (or blade) support rod anddriven by an external drive. The mixing paddles (blades) are separatedlongitudinally along the paddle support rod and are angled to the rodsuch that as the rod is rotated the paddles tend to mix and move thesand laterally through the mixer. Thus, the rotating mixer paddles serveto mix and transport the material.

The paddles may have adjustable pitch, and the drive motor may bevariable speed. The pitch and speed of the mixer paddles will be set bythe residence time required to coat the particles, add curing agents,add waxes and other ingredients and quench (stop the curing at theB-stage) or drive the mix to fill cure (C-stage). In certain cases thecontinuous mixer may be used to coat particles with polymer coats whichdo not require the use of curing agents and other ingredients.

In the rapid action coater system, a continuous sand heater charges thecontinuous mixer. As the heated sand enters the mixer section, moltenresin and/or solid resin is added. The sand and resin are mixed andtravel down the mixer. At the proper point—set by the velocity of thesand/resin mix or by the reactionary stage—further additives areinjected from holding tanks, silos or containers. Similarly at theproper point—also set by the velocity of the sand/resin/additive mix (orreaction stage)—the required solution mix (hexa and water) is added.Further additives may further be injected. The mixture continues downthe mixer where air from an ancillary drier system dries the mixture.The mixture then passes from the mixer and through a shaker screen. Theproduct is then passed through a final screen and sent to storage.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the Prior Art Batch-type mixer

FIG. 2 shows a conceptual schematic of the Instant Invention, using twosegments. The first segment uses a single mixer and the second segmentuses a dual mixer.

FIG. 3A shows a single paddle support rod in the mixer. It should benoted, for clarity, that only one of the plurality of paddles is shown.The arrow indicates the direction of mix flow that is imparted by theturning mixer paddles.

FIG. 3B shows a dual paddle support rod. Again for clarity, only one ofthe plurality of paddles per support rod is shown. The arrow indicatesthe direction of mix flow that is imparted by the turning mixer paddles.

FIG. 4 shows a triple paddle support rod system utilizing two segments.Note the tough-like or nodal shape.

FIG. 5A shows one embodiment of the rapid action coater system detailingthe ancillary units employing a single segment continuous mixer.

FIG. 5B shows another embodiment of the rapid action coater systemdetailing the ancillary units employing a multiple segment continuousmixer. Note the trough-like shape of the continuous mixer shown in thefigure.

FIG. 6 shows a conceptual continuous mixer that splits in two for easeof maintenance.

FIG. 7 shows a temperature and flow chart for the prototype system.

FIG. 8 is a copy of the preliminary engineering design drawing for thecommercial variation of the rapid action continuous mixer.

FIG. 9 shows a control logic chart for the commercial system.

DETAILED DESCRIPTION OF THE EMBODIMENT

Referring to FIGS. 5A and 5B, the instant invention is conceptuallyshown as the rapid action coating system with its required ancillaryunits. Overall there are five main units.

-   -   Unit One—a sand hopper and associated flow control unit        (note—more than one hopper and associated flow control unit may        be used depending on circumstances and required product). {Item        40, 41}    -   Unit Two—a continuous sand heater with associated furnace (or        source of heat) and control system. {Item 42}    -   Unit Three—the continuous mixer: preferably having twin screws.        {Item 44 or 45 and 46}    -   Unit Four—an external blower drier system with associated        controls and dust recovery. {Not shown}    -   Unit Five—a shaker/final screen assembly. {Items 47 and 48}

In addition to the external blower drier system with associated controlsit should be realized that the exhaust air is passed to a scrubbersystem in order to meet air quality control regulations.

The sand heater will contain paddles (or similar) in order to stir thesand thereby bringing the sand into contact with the heater and assuringuniform temperature through the sand. It is possible to combine the sandheater and continuous mixer as a single unit; however, for simplicity,the instant invention will be described as separate units.

Referring to FIG. 2, the continuous mixer is shown with a single screwmixer, 10, having a screw shaft, 12, and associated screw paddles, 11,in the first segment, 1. FIG. 2 shows the second segment, 2, with twoscrews, 50 and 60, screw shafts, 52 and 62, and associated screwpaddles, 51 and 61. Admittedly this conceptual arrangement is strange,but it serves to illustrate two embodiments of the invention in onedrawing. The first embodiment is a single screw (auger) mixer, and thesecond (preferred) embodiment is the dual screw (auger) mixer.

The continuous mixer receives hot sand at the input, 100, and hasinjection ports, 101-106, for additives—wax, clay, oxides, plasticizersand the like, and a hexa/water solution. The actual physical location ofthe injection ports is set by process times and the velocity of the mixtraveling down the mixer. The injection ports are in communication withstorage facilities—tanks or silos as the material requires. Controlvalves (controlled by a control system) open as set by the productrequirements and coat the particles. The term coat is used to meanphysically coating or bonding to the particles as well as “coating” theparticles with additives as required by a particular product. In fact,the additive coating or coatings may be considered as an encapsulationof the coat that is physically bonded to the particle. Some additivecoatings are applied a premix. That is the encapsulation materials arepremixed and then injected into the proper port (or point) in thecontinuous mixer.

For example, based on the batch process described above, the typicalresin charge and mull time is 70 seconds followed by additives andsolutions. (It should be noted that some additives and solution may goin with the sand.) Thus, the distance from the point at which the sandand resin are brought together, to where the first injection port, 101,is located will be given by:

ū/t_(r)

-   -   where ū is the average velocity (feet/sec) of the mix and    -   t_(r) is the resin mix time in seconds.

Similarly the injection point for the hexa/water mix ports, 104 and 105,may be determined as may the entrance port(s) for the drying/coolingair, 107—distributed over a portion of the mixer, 3. Supplementalinjection points may be used.

As stated above, the injection ports can inject a material that bonds toa particle or inject a material that “coats” the particle or both. Thus,coating materials (or ingredients) may mean a material, such as resin,that bonds to the particle; or an additive, such as wax, that coats thebonded material. Different additives (ingredients) are used fordifferent products. The inventors visualize a system were one or moreports are in communication with the same ingredient so that injectionmay occur at a different point in the mixing/coating process. Thecontrol system (FIG. 9) would chose which port is activated for a givenproduct.

The screw mixers, 10, 50 and 60 are driven by variable speed motors andthe paddle pitch may be changed (manually or automatically). Thus, thecombination of paddle pitch and screw (auger) speed will set theresidence time in the continuous mixer. In fact, some paddles may beadjusted to cause the mix to travel backward causing the mixture to“waver” in the continuous mixer thereby increasing the residence time.

FIG. 2 also shows how a two segment continuous mixer is conceptuallyjoined. The input aperture, 100, is shown where prepared particles enterthe first mixer, travel through the first mixer to the intermediateoutput aperture, 111, and travel to the intermediate input aperture,112, and then to the output aperture, 110, both on the second mixer.

A conceptual view of the instant invention, used in the preferred rapidaction coater system, is shown in FIG. 5B as a dual mixer two segmentsystem. The reader must realize that temperatures and times in thisdisclosure are given for illustration only and will be set by the actualproduct required and/or resin being applied to the substrate. (Asubstrate can be a man-made ceramic or naturally occurring material suchas sand.)

Referring now to FIGS. 2, 5A and 5B, sand (or substrate) is stored in ahopper and flow control system, 40 and 41, which are capable ofsupplying a sand heater, 42. Flow from the sand heater is set controlledby an associated sand flow control system, 41. Sand passes through theheater and is brought to a uniform specified temperature by the time thematerial reaches the end of the heater section. The heated sand may beretained in a flow control system, 43. The material then passes into theinput, 100, of the continuous mixer where molten resin and/or solidresin is added to the material via inlet ports, 101-106. The resin andmaterial pass through the continuous mixer. The velocity of the mix isset by the rate of material injection (from the heater), the flow of theresin, the speed (and diameter) of the screw mixer or mixers (10, 50 and60) and the cross-section of the continuous mixer conduit. The mixturepasses down the continuous mixer (in general 44 and specifically 45 and46) where it passes (after the required time period) under the additiveinjection ports, 101-103, thereby absorbing the required additive.

In a similar manner, the mix then passes under the solution injectionport, 104, having spent the required mixing time in the mixer before thesolution is added. Water may be added at port 105 and additionalingredients may be added at port 106. The mix then passes through thedrying section of the mixer, 107, past auxiliary injection ports, 108and 109, and onto the end of the mixer where passes into the shakerscreen/final screener, 47/48, and then to packaging or storage, 49.Supplemental injection ports may be added.

The drying air is maintained at the required temperature by anassociated control system (not shown) and it may be heated, cooled ormaintained at ambient. The exhaust air is passed to a scrubber (notshown) system thereby meeting air quality control regulations.

The design described above may be changed. For example, an optimumdesign would use the preferred twin screw and sequentially introduce theresin to mix on the sand (material), the additives, the hexa solution,cooling the sand while mixing to the so-called “B-stage” buildup andbreakdown. Wax would then be added and the mixture discharged to thescreen. A cooler/dyer may or may not be used. The addition andsequencing of additives, solutions, drying, etc. will vary on the typeof material and desired resin coat. Also, a second continuous mixer maybe used in sequence for the hexa solution addition and other additivesand to facilitate material breakdown. The second continuous mixer may beemployed to add a second coat and a third system may be supplemented toadd a third coating. Rather than employ multiple segments for second andthird coats, additional ports may be incorporated in the mixer to addingredients at the proper time (point).

Design changes are almost unlimited and are up to the design team aswould be set by end user requirements. For example, the first segment inthe continuous mixer may be the sand heater with resin and requiredingredients injected towards the end of the first segment. The secondsegment would continue the mixing process, add the curing agent andquench. Subsequent segments could be added to vary product qualities. Infact all segments could be combined as one very long system. It ispossible to have a dual segment continuous mixing device that onlyapplies a coating in the first segment and allows the particles tocontinue to mix and react in the second segment. Similarly, it ispossible to have no coating in the first segment and only coat in thesecond segment. Thus, the continuous rapid action coater concept is veryadaptable.

As stated above, FIG. 2 shows a continuous mixer divided into twosegments. The first segment, 1, has a single mixer screw, 10, andassociated paddles, 11, mounted to a shaft, 12. The second segment, 2,has the preferred twin screw system, 50 and 60 and associated paddles,51 and 61, mounted to shafts 52 and 62 respectively. FIG. 5A on theother hand shows a single segment continuous mixer that may utilize asingle mixer screw or a dual mixer screw used in the rapid action coatersystem. Thus, the continuous mixer may consist of one or more segmentsand have a trough-like shape (as shown in FIG. 5B). Designconsiderations will set the number of segments. That is, space andcoating requirements. It would be best for the system to have a singlesegment, but some operations may not have the room; hence, the systemmay be split into two or more segments. In fact, the first commercialsystem will employ a dual segment, dual screw mixer as shown in FIG. 8.

FIG. 3A gives details on the paddle arrangement in a single screwcontinuous mixer. The paddles, 11, are mounted to a screw shaft, 12, ata pitch that will insure movement of the sand-mix through the continuousmixer as the screw shaft is rotated. There is nothing critical about thepitch, and it may be chosen by trial an error to lie somewhere between 3degrees to 60 degrees to drive the material forward (If the pitch is toosharp the sand will be mixed and not transported, and, if the pitch istoo flat the same result will be obtained. A person skilled in the artof material transport will have little difficulty in choosing thecorrect pitch.) However, as explained, the pitch may be set to drive themix backward therefore the pitch can range from 0-360 degrees dependingon the function of the particular paddle.

FIG. 3B shows an alternate arrangement for the rapid action coater. FIG.3B shows a twin screw arrangement. Here two screw shafts, 50 and 60, areemployed with a plurality of paddles, 51 and 61, attached to theirrespective shaft. The paddles are carefully set to pass between eachother (mechanical clearance) and employ an angle to ensure movement ofthe sand-mix through the mixer. FIG. 3B actually shows the preferredembodiment. The two screws are designed to turn in opposite directionsthereby moving the mix more efficiently. This is still a design choice.

FIG. 4 provides further detail for a triple screw system, 70, 80 and 90using a two segment variation, 4. Each mixer system has an associatedmixer screw shaft, 72, 82 and 92 along with associated paddles, 71, 81and 91. FIG. 4 also shows how the mixer motors and blades interact witheach other and where the various materials are added in the top mixer.The three bladed mixer/motor combinations may be used in the embodimentsof FIGS. 2, 5A and 5B.

The cross-section of the continuous mixer is shown in FIGS. 3A, 3B and 6(and in FIG. 8) as circle. This is the preferred shape for the prototypeand first commercial units. However, it is anticipated that othercross-sections may be more efficient. For example, FIG. 4 shows a veryconvoluted side view that follows the outline of the mixer paddles. Thepreferred dual screw mixer could set the overall required cross-sectionof the continuous mixer.

FIG. 6 shows a further embodiment of the continuous mixer which utilizessplit housing (in general 99) with two halves, 96 and 95. It was notedduring experimental runs that problems would occur inside the unit and asplit unit was much easier to maintain. The split unit may be hinged(94) on one side and bolted to lips, 98 and 97 on the other side or maybe bolted on both sides. The actual design would hinge on size—a largeunit would be difficult to hinge. In the commercial design, ahydraulically operated clam shell design is employed. This is just anengineering design decision.

As explained earlier, the pitch on the paddles is adjustable. Thus, thepaddles may be set to drive the mix forward or backward in combination.The notion being that the mix will travel down the mixer to a point (orpoints) where the reverse paddle(s) resides, then the mix will reverse,hit additional mix coming forward, change direction, etc. This willensure further mixing and residence times.

FIG. 7 shows a flow chart giving temperatures, injection ports,materials and the like for the prototype unit along with expectedtemperatures. The chart shows chilled water option which can be used ifhigh melting temperature resins are employed and a more rapid quench ofthe chemical reaction is required. In the prototype system the residencetimes in the mixer varied between 40 and 60 seconds. Again this time isset by the requirements of the coating and could be as low as severalseconds to as high as several minutes.

FIG. 8 shows a preliminary engineering design drawing for a commercialunit employing the continuous rapid action coater based on the prototypesystem. The dual screw, dual segment, prototype system had a segmentlength of 32-inches [82 cm], operated at 36 rpm, had a residence time of59 seconds and coated 20 pounds/minute [9 kg/minute] of product. Theprototype system has been scaled up to 1667 pounds per minute [758kg/minute].

The commercial unit employs state of the art computer control whichcontrols the temperature and feed-rate of sand and the feed-rate ofingredients to the mixer. A logic chart is shown in FIG. 9. Thus, theoperator selects the type of product that is to be produced and thecontrol system will then set all parameters, based on retained formulae,to make the particular product. The only possible manual action would beany change of pitch of the screw feeder paddles if a hydraulic pitchcontrol is not used. (The control system would inform the operator ofthe required manual changes—if any.) Finally the control system willcontrol drying/cooling air injection and the speed of the mixer screwsas part of the product manufacture. (Manual selection of the requiredsand silo may be necessary.)

Although it is unlikely, there may be situations in which the coatingprocess requires intermittent transportation of the particles. That is,apply coat materials to the particles, hold the particles in positionfor a period of time, move the particles, apply coating materials, etc.This would be equivalent to a batch operation in a continuous apparatus.This can be accomplished in the instant device by stopping themixing/transportation augers and controlling the feed and ingredients tothe device. Thus, the apparatus can operate in batch mode if necessary.

A person having ordinary skill in the art of material transfer and resincoating of particles can readily understand this disclosure and make thenecessary calculations of residence time, paddle pitch, screw speed,dimensions and etc. Thus, it is believed that there has been fullydisclosed a rapid action coater for adding a resin coat to materials(and, substrates and the like). The unit may be used to coat substratewith polymers.

As described above sequences, times and temperatures may vary and suchvariations are considered to be within the scope of this disclosure. Theinstant device will significantly lower capital equipment costs, willincrease productivity, provide a more consistent product (when comparedto current art batch processes) and reduce energy costs. The instantdevice will also allow for quicker change in product as the device ismore or less self cleaning.

1. A continuous mixer for applying a coating material to particlescomprising: a cylindrical conduit having a first end and a second endand having an inside and an outside; an input aperture located at saidfirst end of said conduit adapted to receive the particles for coating;an output aperture at said second end of said conduit adapted todischarge coated particles; auger means for continuously transportingthe particles from said input aperture to said output aperture; and, aninjection port in communication with and adapted to inject the coatingmaterial from said outside of said conduit to said inside of saidconduit whereby the particles, transported by said auger means,continuously pass under said injection port and whereby the particlesare continuously coated with the coating material.
 2. A continuous mixerfor applying a plurality of coating materials to particles comprising: acylindrical conduit having a first end and a second end and having aninside and an outside; an input aperture located at said first end ofsaid conduit adapted to receive the particles for coating; an outputaperture at said second end of said conduit adapted to discharge coatedparticles; auger means for continuously transporting the particles fromsaid input aperture to said output aperture; and, one or more injectionports, each one of said ports being in communication with a respectivecoating material and each being adapted to inject its respective coatingmaterial from said outside of said conduit to said inside of saidconduit, distributed between said input aperture of said conduit andsaid output aperture of said conduit whereby the particles, transportedby said auger means, continuously pass under said injection ports andwhereby the particles are continuously coated with each of the pluralityof required coating materials.
 3. The apparatus of claim 2 wherein oneof said injection ports is adapted to inject a quench solution onto theparticles passing under said porting means.
 4. The apparatus of claim 3further comprising an air injection port located near said outputaperture for injecting air onto the particles while the particles passby said air injection port.
 5. The apparatus of claim 1 wherein saidauger means further comprises: a single screw auger having a pluralityof paddles whose pitch is adjustable.
 6. The apparatus of claim 2wherein said auger means further comprises: a single screw auger havinga plurality of paddles whose pitch is adjustable.
 7. The apparatus ofclaim 1 wherein said auger means further comprises dual screw augerseach auger having a plurality of paddles whose pitch is adjustable. 8.The apparatus of claim 2 wherein said auger means further comprises dualscrew augers each auger having a plurality of paddles whose pitch isadjustable.
 9. A continuous mixer, capable of intermittent operation,for applying a coating material to particles comprising: a cylindricalconduit having a first end and a second end and having an inside and anoutside; an input aperture located at said first end of said conduitadapted to receive the particles for coating; an output aperture at saidsecond end of said conduit adapted to discharge coated particles; augermeans for intermittently transporting the particles from said inputaperture to said output aperture; and, an injection port incommunication with and adapted to inject the coating material from saidoutside of said conduit to said inside of said conduit whereby theparticles, transported by said auger means, pass under said injectionport and whereby the particles are coated with the coating material 10.The apparatus of claim 8 for applying a plurality of coating materialsand further comprising a plurality of additional injection ports, eachbeing in communication with one of the plurality of coating materialsand each being adapted to inject its respective coating material fromsaid outside of said conduit to said inside of said conduit, distributedbetween said input aperture of said conduit and said output aperture ofsaid conduit whereby the particles, transported by said auger means,pass under said injection ports and whereby the particles are coatedwith each of the plurality of coating materials.
 11. A continuous mixerfor applying a coating material to particles comprising: a firstcylindrical conduit having a first end and a second end and having aninside and an outside; an input aperture located at said first end ofsaid conduit adapted to receive the particles for coating; anintermediate output aperture at said second end of said first conduitadapted to discharge the particles; first auger means for continuouslytransporting the particles from said input aperture to said intermediateoutput aperture; an injection port in communication with and adapted toinject the coating material from said outside of said conduit to saidinside of said conduit located between said input aperture of said firstconduit and said intermediate output aperture of said first conduitwhereby the particles, transported by said auger means, continuouslypass under said injection port and whereby the particles arecontinuously coated with the coating material being injected by saidinjection port; a second cylindrical conduit having a first end and asecond end and having an inside and an outside; an intermediate inputaperture located at said first end of said second conduit incommunication with said intermediate output aperture of said firstconduit an output aperture at said second end of said second conduitadapted to discharge coated particles; and, second auger means forcontinuously transporting the particles from said intermediate inputaperture to said output aperture.
 12. The apparatus of claim 11 wheresaid injection port is translated to said second cylindrical conduit andis located between said input aperture of said second conduit and saidoutput aperture of said second conduit whereby the particles,transported by said second auger means, continuously pass under saidinjection port and whereby the particles are continuously coated withthe coating material being injected by said injection port.
 13. Theapparatus of claim 12 wherein said first segment acts a sand heater. 14.A continuous mixer for applying a plurality of coating materials toparticles comprising: a first cylindrical conduit having a first end anda second end and having an inside and an outside; an input aperturelocated at said first end of said conduit adapted to receive theparticles for coating; an intermediate output aperture at said secondend of said first conduit adapted to discharge the particles; firstauger means for continuously transporting the particles from said inputaperture to said intermediate output aperture; one or more injectionports, each one of said ports being in communication with a respectivecoating material and each being adapted to inject its respective coatingmaterial from said outside of said conduit to said inside of saidconduit, distributed between said input aperture of said first conduitand said intermediate output aperture of said first conduit whereby theparticles, transported by said first auger means, continuously passunder said injection ports and whereby the particles are continuouslycoated with each of the plurality of coating materials; a secondcylindrical conduit having a first end and a second end and having aninside and an outside; an intermediate input aperture located at saidfirst end of said second conduit in communication with said intermediateoutput aperture of said first conduit; an output aperture at said secondend of said second conduit adapted to discharge coated particles; secondauger means for continuously transporting the particles from saidintermediate input aperture to said output aperture; one or moreinjection ports, each one of said ports being in communication with arespective coating material and each being adapted to inject itsrespective coating material from said outside of said conduit to saidinside of said conduit, distributed between said intermediate inputaperture of said second conduit and said output aperture of said secondconduit whereby the particles, transported by said second auger means,continuously pass under said injection ports and whereby the particlesare continuously coated with each of the plurality of coating materials;and, an output aperture at said second end of said conduit adapted todischarge the coated particles.
 15. The apparatus of claim 14 furthercomprising air injection ports distributed between said intermediateinput aperture and said output aperture on said second conduit forinjecting air onto the particles while the particles pass said airinjection ports.
 16. The apparatus of claim 14 wherein said first andsecond auger means further comprise dual screw augers each auger havinga plurality of paddles whose pitch is adjustable.
 17. A rapid actioncoater for continuously applying a plurality of coating materials toparticles comprising: a storage silo adapted to store the particles tobe coated; a first particle flow control system for controlling the flowof particles from said storage silo to; a particle heater adapted toheat the particles connected to; a second particle flow control systemfor controlling the flow of heated particles from said heater to; aninput aperture said input aperture; said input aperture being part of acylindrical conduit having a first end and a second end and having aninside and an outside and wherein said input aperture is located at saidfirst end of said conduit; an output aperture located at said second endof said conduit; auger means for continuously transporting the particlesfrom said input aperture to said output aperture; one or more injectionports, each one of said ports being in communication with a respectivecoating material and each being adapted to inject its respective coatingmaterial from said outside of said conduit to said inside of saidconduit, distributed between said input aperture of said conduit andsaid output aperture of said conduit whereby the particles, transportedby said auger means, continuously pass under said injection ports andwhereby the particles are continuously coated with each of the pluralityof coating materials being injected by said; and wherein said outputaperture is adapted to discharge the coated particles to ascreener-shaker for final delivery of coated particles.
 18. Theapparatus of claim 17 further comprising air injection ports distributedfrom midway between said ends of said conduit and extending towards saidoutput aperture for injecting air onto the particles while the particlespass by said air injection ports.
 19. A rapid action coater forcontinuously applying a plurality of coating materials to particlescomprising: a storage silo adapted to store the particles to be coated;a first particle flow control system for controlling the flow ofparticles from said storage silo to; a particle heater adapted to heatthe particles; connected to; a second particle flow control system forcontrolling the flow of heated particles from said heater to; an inputaperture said input aperture; said input aperture being part of a firstcylindrical conduit having a first end and a second end and having aninside and an outside and wherein said input aperture is located at saidfirst end of said conduit; an intermediate output aperture located atsaid second end of said first conduit first auger means for continuouslytransporting the particles from said input aperture to said intermediateoutput aperture; one or more injection ports, each one of said portsbeing in communication with a respective coating material and each beingadapted to inject its respective coating material from said outside ofsaid conduit to said inside of said conduit, distributed between saidinput aperture of said first conduit and said intermediate outputaperture of said first conduit whereby the particles, transported bysaid first auger means, continuously pass under said injection ports andwhereby the particles are continuously coated with each of the pluralityof coating materials; a second cylindrical conduit having a first endand a second end and having an inside and an outside; an intermediateinput aperture located at said first end of said second conduit incommunication with said intermediate output aperture of said firstconduit; an output aperture at said second end of said second conduitadapted to discharge coated particles; second auger means forcontinuously transporting the particles from said intermediate inputaperture to said output aperture; one or more injection ports, each oneof said ports being in communication with a respective coating materialand each being adapted to inject its respective coating material fromsaid outside of said conduit to said inside of said conduit, distributedbetween said intermediate input aperture of said second conduit and saidoutput aperture of said second conduit whereby the particles,transported by said second auger means, continuously pass under saidinjection ports and whereby the particles are continuously coated witheach of the plurality of coating materials; and, wherein said outputaperture at said second end of said conduit is adapted to discharge thecoated particles to a screener-shaker for final delivery of coatedparticles.
 20. The apparatus of claim 19 further comprising airinjection ports distributed between said intermediate input aperture andsaid output aperture on said second conduit for injecting air onto theparticles while the particles pass said air injection ports.
 21. Theapparatus of claim 19 wherein said first and second auger means furthercomprise dual screw augers each auger having a plurality of paddleswhose pitch is adjustable.
 22. The apparatus of claim 19 wherein saidparticle heater is combined into said first cylindrical conduit therebyremoving the need for a second particle flow control system.
 23. Amethod for continuously coating particles with one or more ingredientcoats in a continuous mixer having a controllable transfer speed and aplurality of coating ingredient injection points thereby producing aproduct with given specifications comprising: a) determining whatproduct is required; b) determining the required coating or coatings; c)determining the transfer speed of the continuous mixer so that thecoating or coatings will adhere as required by the productspecifications to the particles; d) determining the proper injectionpoints that will inject which ingredient; e) preparing the particles forcoating; f) passing the prepared particles through the continuous mixer;g) injecting continuously the determined coating ingredients at theproper points in the continuous mixer; and h) collecting the product.24. The method of claim 23 wherein the following step is added betweensteps g) and h): g-1) cooling the product as required.
 25. A method forcontinuously coating particles with one or more ingredient coats in acontinuous mixer having a controllable transfer speed and a plurality ofcoating ingredient injection points thereby producing a product withgiven specifications comprising: a) determining what product isrequired; b) determining the required coating or coatings; c)determining the transfer speed of the continuous mixer so that thecoatings or coating will adhere as required by the productspecifications to the particles; d) determining the proper injectionpoints that will inject which ingredient; e) heating the particles forcoating; f) passing the prepared particles through the continuous mixer;g) injecting continuously the determined coating ingredients at theproper points in the continuous mixer; h) cooling the product as neededby the product specifications; and i) collecting the product.
 26. Amethod for continuously coating particles with a resin coat and furtherencapsulating the coated particles with ingredients in a continuousmixer having a controllable transfer speed and a plurality of coatingingredient injection points thereby producing a product with givenspecifications comprising: a) determining what product is required; b)determining the required resin coat; c) determining what encapsulationsare required; d) determining the transfer speed of the continuous mixerso that the resin coat and encapsulations will adhere as required by theproduct specifications to the particles; e) determining the properinjection points that will inject the encapsulation ingredient; f)heating the particles for coating; g) passing the prepared particlesthrough the continuous mixer; h) injecting continuously the requiredresin at the proper injection point; i) injecting continuously thedetermined encapsulation ingredients at the proper points in thecontinuous mixer; j) cooling the product; and k) collecting the product.27. A method for continuously coating particles with a coat and furtherencapsulating the coated particles with premixed ingredients in acontinuous mixer having a controllable transfer speed and a plurality ofcoating ingredient injection points thereby producing a product withgiven specifications comprising: a) determining what product isrequired; b) determining the required coat; c) determining whatencapsulations are required, d) determining the transfer speed of thecontinuous mixer so that the resin coat and encapsulations will adhereas required by the product specifications to the particles; e)determining the proper injection points that will inject the premixedencapsulation ingredient; f) preparing the premixed encapsulationingredients; g) heating the particles for coating; h) passing theprepared particles through the continuous mixer; i) injectingcontinuously the required resin at the proper injection point; j)injecting continuously the determined encapsulation ingredients at theproper points in the continuous mixer; and k) collecting the product.28. The method of claim 26 wherein the following step is added betweensteps j) and k): j-1) cooling the product as required.
 29. A rapidaction coater for continuously applying a plurality of coating materialsto particles comprising: a storage silo adapted to store the particlesto be coated; a first particle flow control system for controlling theflow of particles from said storage silo to; a particle heater adaptedto heat the particles; connected to; a second particle flow controlsystem for controlling the flow of heated particles from said heater to;an input aperture said input aperture; said input aperture being part ofa first cylindrical conduit having a first end and a second end andhaving an inside and an outside and wherein said input aperture islocated at said first end of said conduit; an intermediate outputaperture located at said second end of said first conduit first augermeans for continuously transporting the particles from said inputaperture to said intermediate output aperture; one or more injectionports, each one of said ports being in communication with a respectivecoating material and each being adapted to inject its respective coatingmaterial from said outside of said conduit to said inside of saidconduit, distributed between said input aperture of said first conduitand said intermediate output aperture of said first conduit whereby theparticles, transported by said first auger means, continuously passunder said injection ports and whereby the particles are continuouslycoated with each of the plurality of coating materials; a secondcylindrical conduit having a first end and a second end and having aninside and an outside; an intermediate input aperture located at saidfirst end of said second conduit in communication with said intermediateoutput aperture of said first conduit; an output aperture at said secondend of said second conduit adapted to discharge coated particles; secondauger means for continuously transporting the particles from saidintermediate input aperture to said output aperture; one or moreinjection ports, each one of said ports being in communication with arespective coating material and each being adapted to inject itsrespective coating material from said outside of said conduit to saidinside of said conduit, distributed between said intermediate inputaperture of said second conduit and said output aperture of said secondconduit whereby the particles, transported by said second auger means,continuously pass under said injection ports and whereby the particlesare continuously coated with each of the plurality of coating materials;wherein said output aperture at said second end of said conduit isadapted to discharge the coated particles to a screener-shaker for finaldelivery of coated particles; air injection ports distributed betweensaid intermediate input aperture and said output aperture on said secondconduit for injecting air onto the particles while the particles passsaid air injection ports; and a control system wherein said controlsystem controls all aspects of the rapid action coater such as rate ofinput of particles to be coated, preparation steps for the particles,selection of injection ports and respective coating material, rate ofair injection and mixing speeds of the coating process based on chosenproduct requirements.